Lean Maintenance Introduction for Manufacturing Leaders

This workshop provides a guide to the practical steps to deliver high levels of reliability and release scarce Maintenance resources to support Lean Maintenance Value adding activities.

Learning Goals

• Learn what it takes to drive up reliability
• Understand how to make better use of production and maintenance skills to stabilise and extend component life.
• Know how to create a leadership agenda that engages front line teams with delivering zero breakdowns and systematic improvement in effectiveness.
• Be able to guide production and maintenance functions towards proactive improvement in business and bottom line performance.

This course explains the common pitfalls, barriers and drivers of reliability so that delegates are able to complete:

• An assessment of the current shop floor reality based on best practice benchmarks from well respected and award winning organisations
• Short and Long term priorities for attention
• A plan the plan activity to set out practical next steps towards higher levels of reliability.

Deliverables

The course outputs provide a guide to the practical steps to deliver high levels of reliability and redirect scarce skilled resources towards more value adding activities.

This workshop provides a guide to the practical steps to deliver high levels of reliability and redirect scarce skilled resources towards more value adding and more interesting engineering activities.

The gains are significant. They include increased capacity, lower costs and improved flexibility through stepwise actions to:

• Achieve and lock in basic conditions
• Engage front line teams with refining work routines to make them easy to do right, difficult to do wrong and simple to learn
• Target the causes of unplanned interventions and accelerated wear so that it doesn’t fail when the pressure is on.

Deliverables

• • Learn what it takes to drive up reliability
  • Understand how to make better use of production and maintenance skills to stabilise and extend component life.
  • Know how to create a leadership agenda that engages front line teams with delivering zero breakdowns and systematic improvement in effectiveness.
  • Be able to guide production and maintenance functions towards proactive improvement in business and bottom line performance.

This course explains the common pitfalls, barriers and drivers of reliability so that delegates are able to complete:

• An assessment of the current shop floor reality based on best practice benchmarks from well respected and award winning organisations
• Short and Long term priorities for attention
• A plan the plan activity to set out practical next steps towards higher levels of reliability.

Introduction

The Lean Maintenance Road Map

• OEE Stability journey
  Recognising Reliability drivers.
• The Foundations for Zero Breakdowns
  
  • The true causes of breakdowns
  • The journey to zero

Defining Asset Care

• Production and Maintenance Roles.
• Cross Functional Engagement.

Building Capability

• Steps to reduce breakdowns to zero.
• Coaching cross functional teams.

Locking in the gains

• Standard work and visualisation
  Learning and compliance management
• Setting the Leadership Agenda
  
  • Developing a vision the team can get behind
  • Delivering year on year gains

Review of the Workshop

• Benefits, Concerns, Q&A

The workshop content is designed for those faced with the challenge of improving reliability and equipment effectiveness. That includes:

• Business Sponsors and key managers
• Production and Maintenance leaders
• Operations Technical Personnel 
• Manufacturing Engineers
• Change Agents and CI Facilitators

Dennis McCarthy- DAK Consulting
Dennis began his career as an industrial engineer progressing into general management and director level roles. As a consultant he has helped well- respected and award winning organisations to accelerate the pace of improvement. This includes support for internal teams meeting challenges ranging from underperforming assets to company-wide multi-site transformation programmes in Europe, Australia, USA, India and China.